Audi 100 Workshop Service And Repair Manual 1990

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🏷️ Basic Information Identification Make: Audi Model: 100 Model Generation: Fourth Generation (C3/44Q) Codes Chassis Code: 44Q Model Code: Audi 100 👋 Introduction Market Position Market Position: The Audi 100 (C3) was positioned as a premium executive sedan and wagon, competing with models like the BMW 5 Series and Mercedes-Benz E-Class in its era. It was known for its advanced aerodynamics, comfortable ride, and sophisticated engineering. Competitive Analysis Competitive Analysis: The 1990 Audi 100 C3 represented Audi's push into the premium segment, emphasizing technology and luxury. Its design was a significant departure from earlier generations, featuring a more rounded, aerodynamic shape. The availability of quattro all-wheel drive was a key differentiator against many rear-wheel-drive competitors. Key Features Key Features: Aerodynamic design, quattro all-wheel drive option, spacious and well-appointed interior, robust German engineering, and a focus on comfort and stability. 📋 Manual Details Coverage Areas Coverage Areas: Comprehensive service, repair, and maintenance for the 1990 Audi 100 Page Count Page Count: Exact page count not specified in product description, but implied to be comprehensive. Manual Type Manual Type: Workshop Service and Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Systems Covered: Engine mechanical, engine electrical, fuel system, cooling system, lubrication system, exhaust system, transmission (manual & automatic), drivetrain, suspension, steering, brakes (hydraulic & ABS), body electrical, climate control, body repair, interior components, and troubleshooting. Engine Electrical Coverage: Detailed diagnostics for ignition system, fuel injection system (CIS-Jetronic/Motronic), starting system, charging system, and engine control unit (ECU) functions. Includes component testing and troubleshooting flowcharts. Drivetrain Coverage: Covers front-wheel drive axles, driveshafts, constant velocity (CV) joints, differentials (for quattro models), and clutch system (for manual transmission). Suspension Coverage: Front and rear suspension components including struts, shock absorbers, control arms, ball joints, bushings, anti-roll bars, and wheel bearings. Includes alignment specifications. Steering Coverage: Power steering system, steering rack, steering column, and tie rod ends. Includes troubleshooting for leaks and stiffness. Brake Coverage: Hydraulic brake system, front and rear disc brakes, brake calipers, master cylinder, brake lines, and parking brake. Detailed procedures for ABS system diagnostics and repair if equipped. Body Electrical Coverage: Headlights, taillights, interior lighting, power windows, central locking, wipers, horn, instrument panel, warning lights, and fuses/relays. Includes comprehensive wiring diagrams. Climate Control Coverage: Heating system, ventilation, air conditioning (A/C) system components (compressor, condenser, evaporator, receiver-drier), and blower motor. Includes refrigerant charging procedures and system troubleshooting. Body Repair Coverage: Basic body panel removal and installation, adjustment of doors, hoods, and trunk lids. May include information on corrosion protection and sealing. Procedures Included Procedures Included: Routine maintenance, scheduled servicing, component diagnostics, repair procedures, overhaul instructions, electrical system troubleshooting, wiring diagrams, torque specifications, removal and installation of major components, and adjustment procedures. Engine Overhaul Procedures: Step-by-step instructions for engine disassembly, inspection, component replacement (pistons, rings, bearings, valves, camshaft), cylinder head rebuilding, and engine reassembly with critical torque sequences. Transmission Repair Procedures: Detailed procedures for manual transmission disassembly, component inspection, and repair. For automatic transmissions, it will cover fluid and filter changes, valve body diagnostics, and common repair strategies. Clutch replacement procedures for manual models. Suspension Alignment Specs: Specific camber, caster, and toe angle specifications for front and rear suspension, crucial for proper handling and tire wear. Brake Bleed Procedure: Detailed instructions on how to properly bleed the hydraulic brake system, including specific sequences for vehicles equipped with ABS. Wiring Diagrams: Comprehensive, often color-coded, wiring diagrams for all major electrical systems, facilitating efficient troubleshooting of electrical faults. Troubleshooting Guides: Systematic troubleshooting charts and flowcharts for common drivability issues, electrical problems, and mechanical malfunctions. Timing Belt Replacement: Critical detailed procedure for timing belt replacement, including camshaft and crankshaft timing marks, tensioner adjustment, and necessary component removal/installation, crucial for the 5-cylinder engines. Technical Depth Technical Depth: Detailed diagnostic procedures, in-depth repair instructions, and complete overhaul guides, suitable for professional mechanics and experienced DIY enthusiasts. Diagnostic Tools: While OBD-I was in its infancy, the manual will detail the use of specific diagnostic connectors and basic diagnostic equipment relevant to the era's technology. Rebuild Instructions: Instructions for complete engine, transmission, and major component rebuilds, including part specifications and tolerances. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: Assumed high-quality digital reproduction, suitable for printing. Binding Type Binding Type: Not Applicable (Digital PDF) Paper Type Paper Type: Not Applicable (Digital PDF) ⚙️ Engine Specifications Primary Engine Primary Engine: 2.3L 5-cylinder SOHC (Audi NG engine code) Performance Horsepower: Approximately 130-136 hp (depending on specific engine variant and market) Torque: Approximately 190-195 Nm (depending on specific engine variant and market) Fuel System Fuel System: Bosch CIS-Jetronic (Continuous Injection System) or Motronic fuel injection. Fuel Pump Type: Typically an electric fuel pump, either in-tank or external. Engine Variants Engine Variants: While the 2.3L 5-cylinder was common, other variants might have been available globally, including 2.0L and...

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Sku: 91355

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Tags: 100 1990 Audi Car

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Description

🏷️ Basic Information

Identification

Make:

Model:

Model Generation:

Fourth Generation (C3/44Q)

Codes

Chassis Code:

Model Code:

Audi 100

👋 Introduction

Market Position

Market Position:

The Audi 100 (C3) was positioned as a premium executive sedan and wagon, competing with models like the BMW 5 Series and Mercedes-Benz E-Class in its era. It was known for its advanced aerodynamics, comfortable ride, and sophisticated engineering.

Competitive Analysis

Competitive Analysis:

The 1990 Audi 100 C3 represented Audi's push into the premium segment, emphasizing technology and luxury. Its design was a significant departure from earlier generations, featuring a more rounded, aerodynamic shape. The availability of quattro all-wheel drive was a key differentiator against many rear-wheel-drive competitors.

Key Features

Key Features:

Aerodynamic design, quattro all-wheel drive option, spacious and well-appointed interior, robust German engineering, and a focus on comfort and stability.

📋 Manual Details

Coverage Areas

Coverage Areas:

Comprehensive service, repair, and maintenance for the 1990 Audi 100

Page Count

Page Count:

Exact page count not specified in product description, but implied to be comprehensive.

Manual Type

Manual Type:

Workshop Service and Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Systems Covered:

Engine mechanical, engine electrical, fuel system, cooling system, lubrication system, exhaust system, transmission (manual & automatic), drivetrain, suspension, steering, brakes (hydraulic & ABS), body electrical, climate control, body repair, interior components, and troubleshooting.

Engine Electrical Coverage:

Detailed diagnostics for ignition system, fuel injection system (CIS-Jetronic/Motronic), starting system, charging system, and engine control unit (ECU) functions. Includes component testing and troubleshooting flowcharts.

Drivetrain Coverage:

Covers front-wheel drive axles, driveshafts, constant velocity (CV) joints, differentials (for quattro models), and clutch system (for manual transmission).

Suspension Coverage:

Front and rear suspension components including struts, shock absorbers, control arms, ball joints, bushings, anti-roll bars, and wheel bearings. Includes alignment specifications.

Steering Coverage:

Power steering system, steering rack, steering column, and tie rod ends. Includes troubleshooting for leaks and stiffness.

Brake Coverage:

Hydraulic brake system, front and rear disc brakes, brake calipers, master cylinder, brake lines, and parking brake. Detailed procedures for ABS system diagnostics and repair if equipped.

Body Electrical Coverage:

Headlights, taillights, interior lighting, power windows, central locking, wipers, horn, instrument panel, warning lights, and fuses/relays. Includes comprehensive wiring diagrams.

Climate Control Coverage:

Heating system, ventilation, air conditioning (A/C) system components (compressor, condenser, evaporator, receiver-drier), and blower motor. Includes refrigerant charging procedures and system troubleshooting.

Body Repair Coverage:

Basic body panel removal and installation, adjustment of doors, hoods, and trunk lids. May include information on corrosion protection and sealing.

Procedures Included

Procedures Included:

Routine maintenance, scheduled servicing, component diagnostics, repair procedures, overhaul instructions, electrical system troubleshooting, wiring diagrams, torque specifications, removal and installation of major components, and adjustment procedures.

Engine Overhaul Procedures:

Step-by-step instructions for engine disassembly, inspection, component replacement (pistons, rings, bearings, valves, camshaft), cylinder head rebuilding, and engine reassembly with critical torque sequences.

Transmission Repair Procedures:

Detailed procedures for manual transmission disassembly, component inspection, and repair. For automatic transmissions, it will cover fluid and filter changes, valve body diagnostics, and common repair strategies. Clutch replacement procedures for manual models.

Suspension Alignment Specs:

Specific camber, caster, and toe angle specifications for front and rear suspension, crucial for proper handling and tire wear.

Brake Bleed Procedure:

Detailed instructions on how to properly bleed the hydraulic brake system, including specific sequences for vehicles equipped with ABS.

Wiring Diagrams:

Comprehensive, often color-coded, wiring diagrams for all major electrical systems, facilitating efficient troubleshooting of electrical faults.

Troubleshooting Guides:

Systematic troubleshooting charts and flowcharts for common drivability issues, electrical problems, and mechanical malfunctions.

Timing Belt Replacement:

Critical detailed procedure for timing belt replacement, including camshaft and crankshaft timing marks, tensioner adjustment, and necessary component removal/installation, crucial for the 5-cylinder engines.

Technical Depth

Technical Depth:

Detailed diagnostic procedures, in-depth repair instructions, and complete overhaul guides, suitable for professional mechanics and experienced DIY enthusiasts.

Diagnostic Tools:

While OBD-I was in its infancy, the manual will detail the use of specific diagnostic connectors and basic diagnostic equipment relevant to the era's technology.

Rebuild Instructions:

Instructions for complete engine, transmission, and major component rebuilds, including part specifications and tolerances.

📊 Manual Specifications

File Format

File Format:

Print Quality

Print Quality:

Assumed high-quality digital reproduction, suitable for printing.

Binding Type

Binding Type:

Not Applicable (Digital PDF)

Paper Type

Paper Type:

Not Applicable (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Primary Engine:

2.3L 5-cylinder SOHC (Audi NG engine code)

Performance

Horsepower:

Approximately 130-136 hp (depending on specific engine variant and market)

Torque:

Approximately 190-195 Nm (depending on specific engine variant and market)

Fuel System

Fuel System:

Bosch CIS-Jetronic (Continuous Injection System) or Motronic fuel injection.

Fuel Pump Type:

Typically an electric fuel pump, either in-tank or external.

Engine Variants

Engine Variants:

While the 2.3L 5-cylinder was common, other variants might have been available globally, including 2.0L and potentially a 2.8L V6 or diesel options in certain markets. This manual likely covers the dominant engines for the 1990 model year.

Engine Codes

Engine Codes:

Common engine codes for this era include NG (2.3L 5-cylinder), AAR (2.3L 5-cylinder with different valve timing), and potentially others like RT (2.0L 4-cylinder) or AAH (2.8L V6) depending on market variations. The manual likely specifies exact codes covered.

🔧 Transmission

Standard

Standard Transmission:

5-speed Manual Transmission

Optional

Optional Transmission:

4-speed Automatic Transmission (ZF 4HP22 or similar)

Features

Drivetrain:

Front-Wheel Drive (FWD) standard, with optional legendary Audi quattro all-wheel drive system.

📐 Dimensions

Exterior

Wheelbase:

Approximately 2613 mm (102.9 in)

Length:

Approximately 4765 mm (187.6 in)

Width:

Approximately 1775 mm (69.9 in)

Height:

Approximately 1410 mm (55.5 in)

Weights

Curb Weight:

Approximately 1350-1500 kg (depending on configuration and options)

Cargo

Cargo Volume Sedan:

Significant trunk space, typical for a mid-size luxury sedan of the era. Specific volume not provided.

Cargo Volume Wagon:

The Avant (wagon) variant offered substantially more cargo capacity with the rear seats folded. Specific volume not provided.

🛡️ Safety Features

Ratings

Safety Ratings:

Specific crash test ratings for the 1990 model year may vary by region. However, the C3 generation was known for its robust body structure.

Active Features

Active Features:

Anti-lock Braking System (ABS) often available, especially on quattro models. The quattro system itself enhances active safety through improved traction.

Passive Features

Passive Features:

Frontal airbags (driver and passenger) were optional or standard on higher trims. Three-point seatbelts in all seating positions, reinforced side impact beams.

Seat Belts:

Front 3-point inertia-reel seatbelts, rear lap and shoulder belts.

💡 Technology Features

Infotainment

Infotainment Features:

Basic analog or digital radio/cassette systems were common. Climate control systems, often with automatic temperature regulation (Climatronic) on higher trims, were a key technological feature of the era.

Sound System:

Various Audi-branded sound systems were available, from basic 2-speaker units to more advanced 4-speaker or premium systems with equalizers and cassette players.

Driver Assistance

Driver Assistance Features:

The primary driver assistance feature was the optional quattro all-wheel-drive system, significantly enhancing stability and traction in various conditions. ABS was also available.

Connectivity

Connectivity Features:

Limited connectivity by modern standards. Features like power windows, central locking, and cruise control were available on higher trims.

🔧 Maintenance

Service Intervals

Service Intervals:

Typical intervals include: Oil and filter change every 7,500-10,000 miles (12,000-16,000 km) or 12 months. Spark plug replacement typically around 30,000-60,000 miles (48,000-96,000 km). Timing belt replacement is critical, typically every 60,000 miles (96,000 km) or 4-5 years for the 5-cylinder engine (refer to manual for exact specification).

Fluid Specifications

Engine Oil Specification:

Refer to manual for specific viscosity (e.g., SAE 5W-40 or 10W-40) and API service classification (e.g., API SG or SH). Typically 4.5-5 liters for the 2.3L engine.

Coolant Specification:

G11 coolant (phosphate-free, silicate-free coolant with ethylene glycol base). Capacity approximately 8-9 liters.

Brake Fluid Specification:

DOT 3 or DOT 4 brake fluid. Check reservoir level regularly.

Transmission Fluid Specification Automatic:

Dexron III or equivalent ATF. Refer to manual for specific type and capacity.

Power Steering Fluid:

Typically CHF 11S or equivalent power steering fluid. Check reservoir for markings.

Manual Transmission Fluid:

GL-4 gear oil, typically SAE 75W-90 or 80W-90. Capacity approximately 1.5-2.0 liters.

Known Issues

Known Issues:

Common issues can include fuel distributor problems, aging vacuum lines, worn suspension components (bushings, ball joints), electrical gremlins (especially with door locks and climate control), and potential rust in common areas like wheel arches and sills. Timing belt failure can be catastrophic on the 5-cylinder engines, emphasizing the need for strict adherence to replacement intervals.

Common Electrical Faults:

Door lock actuators, central locking pump failure, intermittent dashboard warning lights, and HVAC control unit issues are not uncommon due to age.

Filter Part Numbers

Oil Filter Part Number Example:

Mann-Filter W914/2 or equivalent. Specific part numbers will be detailed in the manual.

Air Filter Part Number Example:

Mann-Filter C23431 or equivalent. Specific part numbers will be detailed in the manual.

📚 Vehicle History

Brand Heritage

Brand Heritage:

Audi, a German automobile manufacturer, has a long history dating back to the early 20th century, known for its engineering prowess and innovative technologies, including pioneering the use of front-wheel drive and quattro all-wheel drive in luxury vehicles.

Model Evolution

Model Evolution:

The Audi 100 C3 (fourth generation) was introduced in 1982 and produced until 1991. The 1990 model year represents a late stage of this generation, featuring refinements in aerodynamics, technology, and safety. It was succeeded by the Audi A6 (C4).

Model Variants:

Available as a 4-door sedan and a 5-door Avant (wagon). Higher performance S4 models were also part of the Audi 100/200 lineage, though this manual is for the standard 100.

Production

Production Years:

1982-1991 (C3 generation)

Manufacturing Location:

Primarily Ingolstadt, Germany

🏆 Awards & Recognition

Recognitions

Recognitions:

The Audi 100 C3 was consistently praised for its aerodynamic design, often cited as one of the most wind-cheating production cars of its time. It was also recognized for its build quality and engineering.